6100... Repairing airbag cables

Attention! 

Only repair those cables which show visible signs of damage. In the event of visible damage, make sure only one cable repair has been made after repairing. If no visible damage can be identified, the entire cable must be replaced. When carrying out repairs to the airbag wiring harness, you must use the spare parts offered in the applicable BMW Parts Catalog. 

Follow safety regulations for HANDLING COMPONENTS OF AIRBAG SYSTEM .

Refer to: INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

In event of non-visible damage to wiring harness: 

Disconnect the plug connection on the airbag module or on the plug adapter. It is absolutely vital to disconnect the contacts in succession as there is a risk of mixing up similar parts! Cut through one cable after the other at an appropriate position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in wiring harness with insulating tape. Now disconnect the plug connection on the airbag control unit. Unpin contacts. Cut through one cable after the other at an appropriate position and insulate with insulating tape, do not under any circumstances cut through both cables at the same time. Pin the contacts of the repair cable for the airbag control unit into the control-unit plug, assignment of repair cables is relevant. Lay repair cable in vehicle parallel to existing airbag lead. Now pin the contacts for the airbag module or the contacts of the plug adapter, assignment of repair cables is relevant. Cut off excess length of repair cable in proximity (visible area) of airbag module or of plug adapter. Twist open cables. With the butt connectors and heat-shrink tubings in the applicable BMW Parts Catalog, reconnect the cables with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.

In event of visible damage: 

Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through both cables at the same time. Now, depending on the work scope, unpin the contacts either on the airbag control unit or on the airbag module or plug adapter. Cut off unpinned cables. Insulate cables remaining in wiring harness with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair cable in vehicle parallel to existing airbag lead up to separation point. Cut off excess length of repair cable. Twist open cables. Connect cables with butt connectors and heat-shrink tubings in applicable BMW Parts Catalog, assignment of repair cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (heat-shrink tubing) with insulating tape to prevent cables from twisting open.

Instructions for cutting off, insulating, crimping cables, installing and removing contacts: 

Refer to: CUTTING OFF AND INSULATING CABLES .

Refer to: REPAIRING A PLUG CONNECTION USING BUTT CONNECTORS .

Refer to: INSTALLING AND REMOVING CONTACTS .